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Designing and building the world largest machine.

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The CAD, PDM and PLM challenges and how CERN solved them.

The CAD, PDM and PLM challenges and how CERN solved them.

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  • 1. Michal Mlynarčík Designing & building the world’s largest machine European Organization for Nuclear Research September 2013 EDMS 1136890
  • 2. Agenda 1. 2. 3. 4. 5. 6. CERN and the LHC accelerator complex Our PLM challenges CERN EDMS – our PLM platform Our CAD challenges CATIA/SmarTeam – our CAD/PDM platform On-going efforts & Conclusions September 2013 EDMS 1136890 3
  • 3. About CERN • CERN is the world’s largest particle physics centre. • Founded in 1954, CERN was one of Europe’s first joint ventures and has today 20 member states and 6 observer states (incl. US & Japan). • CERN provides scientists from all around the world with tools to study the building blocks of matter and the forces that hold them together. • This is done with huge particle accelerators based on cutting edge technologies. • People: ~2.350 staff, ~2.000 contractors and ~10.000 visiting scientists. • Annual budget: ~725 million Euros September 2013 EDMS 1136890 4
  • 4. About CERN September 2013 EDMS 1136890 5
  • 5. About CERN CR: 194 SR: 58 251 Czech nationals 133 Slovak nationals September 2013 EDMS 1136890 6
  • 6. CERN – Facts and fiction • Seeking answers to question about the Universe also advances the frontiers of technology. • The World Wide Web was invented at CERN in 1989 by the British scientist Tim Berners-Lee. • Many other spin-offs: Improved cancer therapy technology, medical and industrial imaging, radiation processing, electronics, measuring instruments, new manufacturing processes and materials,.. • CERN unfortunately does not own an X-33 aircraft as it was suggested in Dan Brown’s book “Angels and Demons”. But we do create anti-matter…. September 2013 EDMS 1136890 7
  • 7. The LHC – our flagship accelerator • The Large Hadron Collider (LHC) consists of millions of high-tech components that are installed in a 27 km long circular tunnel, 100 meters below ground. • Many of these very expensive components will have to be maintained and individually traced for 20-25 years in a partly radioactive environment. • The LHC is the result of an international collaboration involving academic institutes and industries from >80 countries. • Material cost: ~ 4.7 billion Euros September 2013 EDMS 1136890 8
  • 8. The LHC accelerator Bigger is better if you’re searching for the smaller. September 2013 EDMS 1136890 9
  • 9. The LHC accelerator Bigger is better if you’re searching for the smaller. September 2013 EDMS 1136890 10
  • 10. The LHC accelerator Bigger is better if you’re searching for the smaller. September 2013 EDMS 1136890 11
  • 11. ATLAS – one of four LHC detectors The physics is difficult. The engineering is next to impossible. September 2013 EDMS 1136890 12
  • 12. ATLAS – one of four LHC detectors The physics is difficult. The engineering is next to impossible. September 2013 EDMS 1136890 13
  • 13. ATLAS – one of four LHC detectors The physics is difficult. The engineering is next to impossible. September 2013 EDMS 1136890 14
  • 14. The LHC accelerator complex... September 2013 EDMS 1136890 15
  • 15. The LHC accelerator complex... September 2013 EDMS 1136890 16
  • 16. Agenda 1. 2. 3. 4. 5. 6. CERN and the LHC accelerator complex Our PLM challenges CERN EDMS – our PLM platform Our CAD challenges CATIA/SmarTeam – our CAD/PDM platform On-going efforts & Conclusions September 2013 EDMS 1136890 17
  • 17. Our PLM challenges Very long lifecycles and need for internal knowledge transfer. Our installations have lifecycles of more than 50 years. One generation will build the accelerators – the next will operate and maintain it. Design Manufacturing Dismantling CERN EDMS Installation Maintenance Commissioning September 2013 EDMS 1136890 18
  • 18. Our PLM challenges: Complexity • Large, complex and technically advanced. – The accelerator complex consists of some 100 million assets. – Most are unique and the result of many years of R&D. – A cryogenics example to illustrate the technical complexity: • A total LHC cold mass of 37,500 tons is cooled down to 1.9 K (-271 ̊C) in order to enable superconducting magnets to bend and focus proton beams. • Cooling medium: 140 tons of super fluid helium CERN’s helium inventory corresponds to 2% of the EU market. September 2013 EDMS 1136890 19
  • 19. Our PLM challenges: Quality • Quality and control versus innovation and creativity – µm tolerances and kilometer long beam lines. – 40,000 leak-tight welds keeping 700,000 liters of liquid helium in place. – Components are in many cases not accessible once installed - like in satellites! – Easier said than done - especially in a scientific environment! September 2013 EDMS 1136890 20
  • 20. Our PLM challenges: Maintenance • A chain of accelerators and interrelated systems. – The availability of the accelerator complex depends on the availability of the whole chain of injectors and accelerators – some of which are already 50 years old. September 2013 EDMS 1136890 21
  • 21. Our PLM challenges: Operation • Some major operational constraints. – Energy consumption: a town of 150,000 inhabitants (250 MW at peak periods) – Operation between shutdowns : ~1.5 years – Warm-up and cool-down period: 3+3 weeks 4 major breakdowns during operation means no physics that year! • Regulations for nuclear installations. – LHC is classified as a nuclear installation which requires strict traceability of equipment, detailed logs of technical interventions and well documented procedures. September 2013 EDMS 1136890 22
  • 22. Agenda 1. 2. 3. 4. 5. 6. CERN and the LHC accelerator complex Our PLM challenges CERN EDMS – our PLM platform Our CAD challenges CATIA/SmarTeam – our CAD/PDM platform On-going efforts & Conclusions September 2013 EDMS 1136890 23
  • 23. The CERN EDMS – our PLM platform • CERN’s integrated PLM platform is called the CERN Engineering & Equipment Data Management System . • PLM at CERN is consequently not equal to one single system but a set of interfaced applications with several commercial systems as its main pillars. September 2013 EDMS 1136890 24
  • 24. Overview of the CERN EDMS Documents & Components: ~2.500.000 documents & components stored ~6.300 new document & drawings per month ~2,000,000 interventions logged September 2013 EDMS 1136890 Users: ~5.400 registered active users ~120.000 file downloads per month ~8.000 support requests per year 25
  • 25. CATIA/Smarteam & the CERN EDMS integration Data publishing - Published by designer or after reaching state of certain maturity Workflows - Approval and release workflows, versioning rules and access control Viewing of published data - Integrated 3D and 2D viewing in EDMS Archiving - Long term archiving of drawings Accessibility - Fully web-based environment September 2013 EDMS 1136890 26
  • 26. CATIA/Smarteam & the CERN EDMS integration Data publishing - Published by designer or after reaching state of certain maturity Workflows - Approval and release workflows, versioning rules and access control Viewing of published data - Integrated 3D and 2D viewing in EDMS Archiving - Long term archiving of drawings Accessibility - Fully web-based environment September 2013 EDMS 1136890 27
  • 27. CATIA/Smarteam & the CERN EDMS integration Data publishing - Published by designer or after reaching state of certain maturity Workflows - Approval and release workflows, versioning rules and access control Viewing of published data - Integrated 3D and 2D viewing in EDMS Archiving - Long term archiving of drawings Accessibility - Fully web-based environment September 2013 EDMS 1136890 28
  • 28. CATIA/Smarteam & the CERN EDMS integration Data publishing - Published by designer or after reaching state of certain maturity Workflows - Approval and release workflows, versioning rules and access control Viewing of published data - Integrated 3D and 2D viewing in EDMS Archiving - Long term archiving of drawings Accessibility - Fully web-based environment September 2013 EDMS 1136890 29
  • 29. CATIA/Smarteam & the CERN EDMS integration Data publishing - Published by designer or after reaching state of certain maturity Workflows - Approval and release workflows, versioning rules and access control Viewing of published data - Integrated 3D and 2D viewing in EDMS Archiving - Long term archiving of drawings Accessibility - Fully web-based environment September 2013 EDMS 1136890 30
  • 30. Agenda 1. 2. 3. 4. 5. 6. CERN and the LHC accelerator complex Our PLM challenges CERN EDMS – our PLM platform Our CAD challenges CATIA/SmarTeam – our CAD/PDM platform On-going efforts & Conclusions September 2013 EDMS 1136890 31
  • 31. Specific CAD challenges at CERN • Micrometer precision models assembled in installations ranging over several kilometers. • Multidisciplinary environment. • Large international collaborations with an extreme multi-CAD environment. (At LHC project start-up some 20 different tools were identified!) September 2013 EDMS 1136890 32
  • 32. Precision Micrometer precision for RF structures ... -Export to stress analysis tools and for machining ... in instalations ranging over several km. -Multilevel skeleton models with local coordinates September 2013 EDMS 1136890 33
  • 33. Precision Micrometer precision for RF structures ... -Export to stress analysis tools and for machining ... in instalations ranging over several km. -Multilevel skeleton models with local coordinates September 2013 EDMS 1136890 34
  • 34. Precision Micrometer precision for RF structures ... -Export to stress analysis tools and for machining ... in instalations ranging over several km. -Multilevel skeleton models with local coordinates September 2013 EDMS 1136890 35
  • 35. Precision Micrometer precision for RF structures ... -Export to stress analysis tools and for machining ... in instalations ranging over several km. -Multilevel skeleton models with local coordinates September 2013 EDMS 1136890 36
  • 36. Precision Micrometer precision for RF structures ... -Export to stress analysis tools and for machining ... in instalations ranging over several km. -Multilevel skeleton models with local coordinates September 2013 EDMS 1136890 37
  • 37. Multidisciplinary environment Civil Engineering Metallic Structures CATIA V5 used by various disciplines Cooling & Ventilation Power Devices Accelerator & Mechanical Equipments September 2013 Radio Frequency EDMS 1136890 38
  • 38. International collaboration September 2013 EDMS 1136890 39
  • 39. Agenda 1. 2. 3. 4. 5. 6. CERN and the LHC accelerator complex Our PLM challenges CERN EDMS – our PLM platform Our CAD challenges CATIA/SmarTeam – our CAD/PDM platform On-going efforts & Conclusions September 2013 EDMS 1136890 40
  • 40. • CATIA was bought at CERN in 2003 to replace Euclid. • After a first CATIA pilot project, the system has been since 2005 in production, and full speed since 2007. • Euclid was permanently stopped at CERN in Dec 2008 after an intense migration period ~500 man-years of design work migrated. • CATIA is today the only official and centrally supported 3D CAD tool at CERN with ~250 users. 1983 2003 1993 Euclid Dec. 2008 Euclid 3 CATIA September 2013 EDMS 1136890 41
  • 41. CATIA/SmarTeam at CERN Current version and upgrade plan Current release of CATIA/SmarTeam: Next release to upgrade to: Target date for upgrade: Current Implementation One CAD system for all (at CERN): PDM with strong CAD integration: Item Centric approach: Domain Data management in CATIA/SmarTeam September 2013 R20 R23 October 2013 CATIA V5 SmarTeam SmarTeam & EDMS Specific modules Tool CAD data management Item management BOM data management CATIA/SmT integration BOM Compare tool CartWeb tool EDMS 1136890 42
  • 42. CAD management Marec 2011 EDMS 1136890 43
  • 43. CAD management Marec 2011 EDMS 1136890 44
  • 44. CAD management Marec 2011 EDMS 1136890 45
  • 45. CAD management Marec 2011 EDMS 1136890 46
  • 46. CAD management CATProduct 1 CATProduct 2 CATPart 1 CATPart 2 CATPart 3 CATProduct 3 CATPart 4 CATPart 5 Marec 2011 EDMS 1136890 47
  • 47. CAD management CATProduct 1 CATProduct 2 CATPart 1 CATPart 2 CATPart 3 CATProduct 3 CATPart 4 CATPart 5 Marec 2011 EDMS 1136890 48
  • 48. Item Management Marec 2011 EDMS 1136890 49
  • 49. Item Management Marec 2011 EDMS 1136890 50
  • 50. Item Management Marec 2011 EDMS 1136890 51
  • 51. Item Management CATProduct 1 CATProduct 2 CATPart 1 CATPart 2 CATPart 3 CATProduct 3 CATPart 4 CATPart 5 Marec 2011 EDMS 1136890 52
  • 52. Item Management Assembly 1 Sub-assembly 1 Part 1 Part 2 x 2 Part 3 Sub-assembly 2 Part 4 Part 5 Marec 2011 CATProduct 1 CATProduct 2 CATPart 1 CATPart 2 CATPart 3 CATProduct 3 CATPart 4 CATPart 5 EDMS 1136890 53
  • 53. Item Management Assembly 1 Sub-assembly 1 Part 1 Part 2 x 2 Part 3 Sub-assembly 2 Part 4 Part 5 Glue Marec 2011 CATProduct 1 CATProduct 2 CATPart 1 CATPart 2 CATPart 3 CATProduct 3 CATPart 4 CATPart 5 EDMS 1136890 54
  • 54. BOM management Marec 2011 EDMS 1136890 55
  • 55. BOM management Marec 2011 EDMS 1136890 56
  • 56. BOM management Marec 2011 EDMS 1136890 57
  • 57. BOM management Marec 2011 EDMS 1136890 58
  • 58. CATIA SmarTeam Demo You can watch demo videos demonstrating CATIA SmarTeam BOM item management at CERN and more on my media channel: http://vimeo.com/michalmlynarcik September 2013 EDMS 1136890 59
  • 59. Agenda 1. 2. 3. 4. 5. 6. CERN and the LHC accelerator complex Our PLM challenges CERN EDMS – our PLM platform CATIA/Smarteam integration CATIA/SmarTeam – our CAD/PDM platform On-going efforts & Conclusions September 2013 EDMS 1136890 60
  • 60. Recent and on-going projects • Integration of SmarTeam with Oracle Agile e6 CERN is currently in the process of integrating our PDM SmarTeam with the corporate PLM Agile e6 from Oracle. • Free public 3D CAD viewing In order to visualize and evaluate the 3D data outside PDM, users can download data converted to the 3DVIA Composer format and open it with the free 3DVIA Composer Player • Offline EDMS viewer With a new CERN-developed offline viewer, maintenance technicians can browse documents in the field on a laptop instead of large paper folders. September 2013 EDMS 1136890 61
  • 61. Recent and on-going projects • Strong focus put on Item management – Moved from a document-centric to an itemcentric approach in the design offices. – Equipment groups are documenting their equipment using BOMs and technical data. – Increased efforts in the traceability of material compositions for radioactive waste purposes. • Documenting the existing machines – EDMS has proven very useful for the LHC, now the already existing machines are being documented in the same standardized manner using the same tools. – This also means scanning both paper drawings and microfilm. – Items and documents are registered for 50 years old machines and installations. September 2013 EDMS 1136890 62
  • 62. Conclusions Our current strategy: A local PDM for the design offices and a global PLM for the whole organization. 3DVIA Composer suite of software proved to be valuable asset - The 3DVIA Enterprise batch translation publishes the 3D data to the PLM on demand The 3DVIA Composer Player is a freely available software which allows users to view and evaluate the published data SmarTeam became the work horse of the CERN CAD - It enabled to us concentrate on further enhancements and integration with the PLM system The future of SmarTeam is counted, but so long we haven't been able to identify the successor Dassault will one day replace CATIA V5 and SmarTeam with V6 - Our current evaluation of CATIA V6 proved to be not conclusive Will our current strategy remain valid with two full-fledge PLM systems available? What is the license strategy of Dassult Systémes concerning the research branch? September 2013 EDMS 1136890 63
  • 63. Conclusions Where are the long-term savings for CERN? – – The integrated PDM platform has forced engineering groups to follow common working methods. The collaborative environment of SmarTeam allowed designers work on complex engineering tasks in a highly diverse and volatile setting of CERN Keys to success for the PDM implementation at CERN; – – – – • A global plan and strong management support. A support and consulting team working closely with the user groups. A significant training campaign – over 500 people have been trained. A long-term vision – the PDM project at CERN started 1993 Implementing PDM in a scientific environment is possible and is an absolute must for a laboratory like CERN. September 2013 EDMS 1136890 1-day 2-day Introduction course Administration course 1-day 1-day Introduction course Engineering course ½ -day MTF course 64
  • 64. e-mail: Ing.Michal.Mlynarcik@gmail.com